Method of producing alkali metals.



JOHN E. BUGHEB, or oovnivrnx, RHODE ISLAND;

Mn'rrron or rnonuome ALKALI METALS.

No Drawing.

Specification of Letters Patent.

Patented Dec. 2, 1913.

. Application filed July 22, 1912. Serial No. 710,758.

To all whom it may concern:

Be it known that I, JOHN E. BUCHER, a citizen of the United States, residing at Coventry, in the county of Kent and State of Rhode Island, have invented certain new and useful Improvements in Methods of Producing Alkali Metals, of which the following is a full, clear, and exact description. This invention relates to the preparation or derivation of metals, and especially the alkali metals, 6. 9., sodium and potassium, from their cyanogen compounds'or derivatives, or the like, bythe action of heat upon their cyanids, ferro-cyanids, ferri-cyanids, etc., in the presence of elements which absorb, dissolve or react with one, at least, of the non-metallic constituents of such a compound at a suitable temperature. Sodium and potassium, for example, were formerly prepared by heating alkali carbonates or hydroxids with carbon, as exemplified by the following equations:

1 x oo +eo=ex+eoo 2 2K0H+20=2K+200+H These reactions require an objection-ably high temperature and the carbon monoxid thus formed has a strong tendency to combine with the liberated metal, especially to form dangerous explosive compounds, such as C O K while ittends also to reform the carbonate; equation 1 being a reversible one. These disadvantages and the resulting expense and danger led to the practical abandonment of such non-electrolytic methods and the development of the modern electrolytic processes.

In my work on the synthesis of cyanids and on the purification of iron (applications for Letters Patent for processes relating to the latter of which have been filed in the United States Patent Ofiice, being'there identified respectively as applications Serial Number 676,399, dated Feb. 8, 1912, and Serial Number 690,886, dated April 15, 1912), vI discovered a non-electrolytic method for preparing metals such as sodium or potassium, which avoids the danger and difliculties of the older methods and which yields byproducts which are of special value, particularly in connection with my processes for the purification of metals.

Reference may here be made to my copending applications relating to the synthes1s and production of cyanids and the like;

said applications .being respectively designated Serial No. 711,211, filed July 24, 1912, entitled Synthetic production of cyanogen compounds and the like, and Serial No. 726,924, filed October 21, 1912', entitled Process for fixing atmospheric nitrogen. It is obvious that by operating the herein described process in conjunction or incombination with the economic processes for producing cyanogen compounds which I have invented and to which the said applications will relate, or with any other suitable and commercially inexpensively operated process of. cyanid formation, alkali metals may beproduced non-electrolytically, cheaply and in abundance. I desire, however, to lay particular emphasis on the value of the present process, in view of the use of alkali metals in my processes for decarbu-l rizing steel and the like.

Considering more-particularly the present process: I have discovered that while the cyanids of sodium or potassium, for ex- .ample, can be distilled substantially unchanged in vessels of porcelain, or hard glass, when the distillation is conducted in iron tubes, nitrogen is given off steadily and free metal, 6. g., sodium or potassium, is deposited on the colder portions of the tube or vessel. Still better results were obtained by heating a mixture of powdered or 2K+carbonized iron-I-N (4) 2NaCN+iron= I 2Na+carburized 'iron-l-N 5) K,Fe CN) -l-iron:

4K+carburized iron+3N When the temperature and other conditions are suitable, the alkali metals distil p from the reaction mixture in substantially obviously pure form. Incidentaliliy nitrogen, free from argon, is given 0 As oxygen-free compounds are used, the method also avolds the serious danger of explosions resulting from the carbon monoxid produced by the older methods. When iron is used, carburized iron is obtained as another by-prodnot. The carbon may be removed from this carburized iron, thus:

6 Carburized iron+QK+N QKCN-kiron 7 (,larburized iron+2Na+N Q 2iTaCN-l-iron or by other suitable reactions such as;

(8) Oarburized ir0n+O =iron+2CO The decarburized iron thus obtained can i iiing with one, at least, of these elements 'mff a in any event with that one of said elements which might directly combine with the alkali metal base after the cyanogen compound has been broken down. Neither sodium nor potassium can so directly combine vwith either carbon or nitrogen under the conditions of the operation, but lithium may, as will be hereinafter more fully considered. Since the alkali metal base of the cyanogen compound is incapable, under the imposed conditions, of directly and separately uniting with either of said non-metallic elements, said base is liberated in free or molecular condition. The contact between the radical-dissociating reagent and the cyanogen compound should preferably be as intimate as ossible, and it is for this reason that I pre erto use said reagent in finely divided condition when the temperature of the operation is such that the reagent is in non-fluid or solid form. If the reagent used is a metal or element which forms a nitrid as well as a carbid under the conditions of the process, then a mixture of nitrid and carbid may be formed. For

example 9 3KON+7Alr.-,A1,C,+3A1N+3K or, nitrid alone might form,

be used over again, in a cyclic hatever be the metal or material The alkali metal from the cyanid in these latter cases may be separated, as before, from the non-volatile carbids and nitride.

The nitrids may then be used in-variousv ways, 6. 9., to form ammonia and aluminium compounds (1f alum nium be the dissociating material or reagent employed), or even to reform the aluminium itself, thus making the action of the aluminium cyclic. The fact thatv the alkali metal sought has in each case a lower temperature of volatilization than the remaining products of .the reactions in question is of considerable importance since distillation from the already heated reaction products affords a simple and inexpensive means for obtaining such metal in a substantially pure condition; no subsequent refining-process bein necessary. Equations 3 and 6, for examp e, may be written thus: (11) 2KCN+ironS 2K+carburized iron-i-N,

the reaction involved being a reversible one and depending upon the relative active masses of the respective reacting materials or elements present; or-in other words upon what is known as the law of mass action. Thus, if metallic sodium, carbon and pulverulent iron (or carbid of iron) be heated to dull redness, while intimately commingled, and while passing a current of atmospheric nitrogen thereover or through, the reaction is exothermic and results in the formation of sodium cyanid; while, on the other hand, if sodium cyanid and finely divided iron be heated, preferably, although not necessarily, to a somewhat higher temperature, the reaction is endothermic and yields metallic sodium in the manner hereinbefore described.

I am aware that various materials may be substituted for those particularly specified and that other changes may be made in the manner of elfectuating my process without departing from the spirit of my invention and I hencev desire to be limited only by the claims appended hereto. It may be stated, however, that owing to the peculiar efficiency of iron in the process and in view of the relatively non volatile by-products resulting from the use of this substance therein, I regard it as the preferred reagent and have hence-particularly referred to 1t in certain of the more limited claims. A plurality of dissociating reagents may be used in certain cases, as, for example, iron and aluminium. Wherever, however, distillation is to be resorted to as the means for separating the freed alkali metal from the products of the reaction, it is obvious that both the dissociated reagent and the alkali metal compound used should be so selected that'said products of reaction other than For example:

the liberated alkali metal shall have boiling points higher than that of the alkali metal.

The temperature of the operation should be above 500 C., or in other words, little, it any, 'below a dull red 'heat but may range from thence upward to 1200 C., or higher. Where the iron is used in solid form, it is preferable to operate at temperatures below this last mentioned figure on account of the cost of fuel or energy and up-keep of the apparatus.

Since, as intimated in the opening paragraph of this specification, the carbon, for example, of the alkali metal compound may be absorbed by, dissolved in, or reacted with the dissociating reagent, 6. 9., iron, the Word combine or its derivatives, has been used in certain of the appended claims, for want of a better generic term, tocover this and like actions; said word being of sufficient breadth to include both chemical combination or union, and physico-chemic'al combination such as occurs in absorption, ad: sorption and solution.

In conclusion I desire to emphasize the fact that while sodium and potassium may be produced in the manner indicated at temperatures preferably approximating a bright red heat, the alkali metal lithium, owing to the fact that it may be readily combined directly with nitrogen, cannot in all cases be obtained as a free metal at such a temperature; while the action of heat I alone may cause, the cyanid thereof to break At a very high temperature, metallic lithium might be obtained from its nitrid.

\V here aluminium or some like nitrid forming element or elements is used to break down the cyanid, I am of the opinion that it is possible that free metals such as lithium and calcium may be obtained because ofthe great afiinity of aluminium for nitrogen.

(13) Li,N+Al=-A1N+3Li.

In like manner:

(14) LiCN+Al:AlN-|-Li+C Sodium and potassium are, however, I consider, the most commercially valuable metals which may be obtained by my process and I have hence directed the more specific claims particularly thereto.

I have termed such alkali metals as sodium and potassium, which will not directly unite with the liberated nitrogen .nnder the imposed conditions, non-nitrid forming metals.

By the term cyanogen compound I contemplate any compound which includes the radical CN as a constituent thereof.

I Having described my invention, I claim: 1. The process of producing alkali metals which comprises reacting on a cyanogen compound of the alkalimetal sought, with an'element incapableof directly chemically combining with said metal but capable of dissociating the element carbon from the elemerit nitrogen of said compound by directly combining with one of said elements, and

thereby liberating said alkali metal.

2. The process of producing alkali metals which comprises re cting on a cyanogen compound of the al ali metal sought, with a reagent incapable of directly chemically combining with said metal but capable of dissociating the carbon from the nitrogen of said compound by directly combining with said carbon, and thereby liberating said alkali metal.

3. The process of producing alkali metals which ,comprises reacting on acyanogen compound of the alkali metal sought, with iron to form carburized iron and to thereby liberate said alkali metal.

4. The process of producing alkali metals which comprises bringing a cyanogen compound of the alkali metal sought into intimate contact with finely divided iron and 'eflecting a chemical reaction therebetween at an elevated temperature, whereby to form iron carbid and to liberate nitrogen and the alkali metal.

5. The process of producing alkali metals which comprises bringing the cyanid of the alkali metal. sought into intimate contact with a finely divided metal capable of separately combining with one of the two nonmetallic constituent elements of said cyanid and effecting a reaction between said cyanid and said finely divided metal at an elevated temperature, whereby to liberate both said alkali metal and the other of said nonmetallic elements.

6. The process of producing alkali metals which comprises bringing the cyanid of the alkali metal sought into intimate contact with finely'divided iron and effecting a reaction therebetween through the instrumentality of heat, whereby to liberate both said alkali metal and nitrogen.

7. The cyclic process of producing alkali metals which comprises reacting on a cyanogen compound of the alkali metal sought, with a metallic reagent capable of dissociating said compound by directly combining separately with one of the non-metallic constituent elements thereof, and thereby liberating said alkali metal and another of said elements, thereafter separating said metallic reagent from the non-metallic element so combined therewith, and repeating the cycle.

8. The process of producing alkali metals which comprises effecting an endothermic reaction at an elevated temperature, between ble of separately combining with .one of the constitue t elements of said radical, whereby -to liberat said alkali metal.

10. The process of producing alkali metals which comprises effecting an endothermic reaction, at an elevated temperature between a compound of said alkali metal whichincludes a radical one of the two constituents of which is nitrogen, and a sub stance capable of separately combining with one of the constituent elements of said radical, whereby to liberate said alkali metal, and separating said alkali metal from the products of said reaction by distillation.

11. The process of producing alkali metals which comprises effecting an endothermic reaction at a temperature above 500 C. between a compound of said alkali metal which includes a radical one of the two constituents' of which is nitrogen, and a substance capable of separately combining with one of the constituent elements of said radical, whereby to liberate said alkali metal.

12. The process of producing alkali metals which comprises effecting an endothermic reaction, at -a temperature below 1200 0., between a compound of said alkali metal which includes a radical one of thetwo constituents of which is nitrogen, and a substance capableof separately combining with one of the constituent elements of said radical, whereby to liberate said alkali metal.

13. The process of producing alkali metals which comprises effecting an endothermic reaction at a temperature materially below a white heat. between a compound of said alkali metal Which includes a radical having two constituent elements .one at least of which is incapable of directly and separately uniting with said alkali metal, and material capable of separately combining with the other of said constituent elements of said radical, whereby to dissociate said radical and liberate the alkali metal.

14. The process of producing alkali metals which comprises effecting an endothermic reaction between acompound of said alkali metal which includes a radical having two constituent elements both of which are incapable of directly and separately uniting with said alkali metal, and material capable of separately combinin with one of said constituent elements 0 the radical, whereby to dissociate said radical and lib erate the alkali metal.

15. The method of producing a substantially pure alkali metal which comprises reacting endothermically upon an oxygen free compound of the alkali metal sought and which compound includes a radical, with a material capable of separately combining with one of the constituent elements of said radical, whereby to dissociate the latter and liberate alkali metal, and separating said alkali metal from the products of said reaction by distillation, said compound and said material being such that one of said products has a boiling point materially below that of the alkali metal and the said products of the reaction other than said one and the free alkali metal have boiling points higher than that of said alkali metal.

16. The process of producing the alkali metals sodium and potassium which comprises reacting on a cyanogen compound of the alkali metal sought, with an element incapable of directly chemically combining with said metal but capable of dissociating the element carbon from the element nitrogen of said compound by directly combining with one of said element to thereby liberate said alkali metal.

17. The process of producing the alkali metals sodium and potassium which comprises reacting on a cyanogen compound of the alkali-metal sought, with a reagent incapable of directly chemically combining with said metal but capable of dissociating the carbon from the nitrogen of said compound by directly combining with said carbon, and thereby liberating said alkalimetal.

18. The process of producing alkali metals which comprises bringing the cyanid of the alkali metal sought into intimate contact with a finely divided metal capable of separately combining with one of the two non metallic constituent element of said cyanid and effecting a reaction between said cyanid and said finely divided metal at an elevated temperature, whereby to liberate both said alkali metal and the other of said non-metallic elements, neither of said nonmetallic elements being able to directly and separately combine with the liberated alkali metal, under the conditions of the operation, substantially as described.

19. The process of producing alkali metals which comprises bringing a cyanogen compound ot the alkali metal sought into intimate contact with anelement capable ofseparately combining with one of the non-metallic constituent elements of said compound and effecting a reaction between said compound and said first mentioned element at an elevated temperature, whereby to liberate both said alkali-metal, and another of said In witness whereof, I subscribe my signanon-metallic elements, neither of said nonture, in the presence of two Witnesses. metallic constituent elements of said compound being able to directly and separately JOHN BUCHER' combine with the liberated alkali metal Witnesses:

under the conditions of the operation, sub- WALDO M. ORA-PIN, stantially as described. D IDA M. PATTERSON.. 

